Mattress



Ma? 741946 M. CUNNINGHAM 2,399,62@

MATTRESS Fild April 19, 1945 2 Sheets-Sheet l M. M. CUNNINGHAM MATTRESSFiled April 19, 1943 2 Sheets-Sheet 2 i Patentedl May UNITED s'rA'rEs,PA

MAESS Marion Morgan Cunning, South t* :s

Ind.,

assigner to Misha 'Rubi' Woolen Manufacturing Company, Mishawoha, lind.a

corporation oil i t t n Application April ld? i943, Serini No. imite@-The present invention 'relates to mattresses, and particularly tocombined inner spring and nge rubber mattresses.` The invention, ingeneral, aims to provide a highly serviceable e d comfortable -mattreseby assembling a io sponge rubber pad with a spring unit or units made upof a number of coil springs. y

d. ille obiect of the invention is to provide u ttress oi the chnracterindiceted, inclu 'v a ent spongy rubber body supporting eieent or pad,`n spring assembly d e, severine or r thereior, which may bey easilydisneeebied when it is denied to substitute other spring its oi greateror lesser resiliency, or wen thas pad end ticking is to be washed and/orits im er obiect is to provide a mattress construction which permits airto rmeate oi its walls for thorough and continuousventilation. d

ther object is to provide separate but united iabric compartments ici'the pad and springs, so

liti

liti' that the pad may be anchored to the springs vet may be easilyremoved therefrom, along with the fabric.

Other objects are to unite the metallic u ivi with soft foam rubber insuch a way that th foam rubber cmmot be torn or cut by ordinary. usage;to protect the user under all conditionsA from contact with the springunit; to provide a i mattress of pleasing appearance so that it isreadily salable; to facilitate sliding the spring unit in and out oi thefabric compartment; and to provide a mattress which may be sold at nreasonablevcost.

Still another object of the invention is to provide, in a mattresshaving a spongy rubber body supporting member, an arrangement utilizinga plurality of spring units of differing tension, strength or supportingpower whereby the mattress, and particularly the upper part thereof,hasample compressibility and resilience accompanied by a high hysteresisvalue as a whole, ir-

4ticking employed.

With these and other objects in view theinvention resides in theconstruction, operation and novel combination and arrangement of partshereinafter fully described, illustrated in the accompanying drawingsand particularly pointed out inthe appended claim, it being understoodthat various modifications may be made in the se or sooo any ci theadvantages thereof.

lin the accompanying drawings: Fig. ll is u perspective view of one formof mattrees embodying features oi the present invention shown suppo on.a conventional box spr ioundation or beadstead;

ldt. 2 is a partial perspective view. on a larger scale, or the mattressseen in Fig. 1, showing the mattress cover or tic opened at one end, astor insertion or withdrawaloi the spring unit;

Fig. d is an end elevation, looking at the mattress oi Figs. l. and 2.trom the right-hand end thereof, with parts in section; Y 1

ii is n transverse cross section, as on th line t-t oi Fig. l. showingthe mattress depressed as when supporting a person and also sho ineievetion the upper portion of the box sp tu ioundntion;

Fig. o "is e, fragmentary vertical section on a larger scale showing theattachment of tape to the foam rubber pad for the securing of the tici:uing thereto;

Fig. d is a fragmentary vertical section through the pad on the scale ofFig. 5 showing the manner oi' securing it to the fabric envelope orticking which encloses the springs; and

Fig. "i is an end elevational view, partly in section, sho a modied formof mattress wherein e i units of diil'ering supporting power areemployed.

in general, the present invention, according to an important aspectthereof, comprises an enveloping casing or mattress ticking in an upperportion or compartn'nent of which is secured preferably in a more orless permanent fashion, a pad or body supporting member of spongerubber. Such pod is preferably of the type molded of an aqueousdispersion of latex which has been whipped into a foam in the presenceof a frothing agentl or which has been combined with a separatelyprepared foam, and generally contains internal cavities formed in themolding operation.-

' Underneath the seid pad the ticking is formed, respective of theparticular type of covering or mattresses; At one end of the springcompartmentthe ticking walls are divided or slitted to form, proportionand minor details and arrange t ment of parte. within the scope of theclaim, without departing' from' the spirit of the invenafford an openingfor the ready insertion or removal of the spring unit, and are providedwith suitable fastener elements to maintain the opening closed when thespring unit is within the compartment.

According to a further aspect of the invention the ticking withcontained rubber pad may be provided with two lower compartments for thereception of two individual spring units which, preferably, may havediffering characteristics as to stiffness, supporting power, and thelike. In this aspectI of the invention the ticking is preferablyprovided with an opening or openings for the ready insertion and removalof the springs. The latter feature, however, -is not necessarily anessential component, since the providing of a mattress comprising asponge r'ubber pad and a pair of springs of differing characteristics,all enclosed within an enveloping ticking, is deemed to constitute anovel and important aspect of the present invention, irrespective. oiwhether the spring units are readily removable from the ticking or aresubstantially permanently incorporated therewithin.

In accordance with a preferred form of the invention, I employ a coilspring unit I of conventional construction embodying heavy marginal orframe rods or Wires II, coil springs I2 and tie wires I3 connecting thecoil springs to each other and to the marginal -wires II. The latter arepreferably covered with suitable padding material IIa forthe purposes ofcomfort and the prevention of damage to the ticking or casing presentlyto be described. Such a unit is extremely flexible, in' fact it willyield in every direction, and it is excellently adapted for supporting afoam rubber pad if the pad is properly anchored and adequatelyprotected. against the cutting'or tearing action of the upper ends ofcoil springs I2. It will be understood that foam rubber is extremelysoft and does not have a great deal of strength, but because of itslcompressibility and low internal friction, and for other reasons knownto those skilled in the art, it is highly desirable for use inmattresses.

The foam rubber pad I4 (Fig. 3 et seq.) may be from one to two inches inthickness and preferably is both wider and longer than the spring unit,so that when assembled with the spring unit it overhangs the marginalwires II on all sides by about one inch. All the edges of the pad aremade more flexible by being beveled both from the top and from thebottom, as best shown in Figs. 5 and 6, said beveling being indicated atI6 and I1 and obviously comprehendlng the overhanging portion of thepad. On the underside,

the pad- I4 has a large number of preferably cupshaped recesses orcavities lIii not only to increase the compressibility of the pad, butalso to insure adequate and continuous ventilation thereof, as will beexplained. The described pad must be protected by a cloth casing, towhich it should be secured immovably without interference with flexingof the pad, and toA this end a heavy cotton duck or other porous clothsheet I8 is stretched over the top of the pad, while a similar or evenheavier fabric sheet I8 is stretched over the bottom of the pad. bothsheets I8. I9 being stitched together, as indicated at 20, outside thethin edge provided by bevelingv I 8, I1. Cloth tape 2| may be securedover the'seam by the stitching 20 to make a better appearance. To

y anchor the sheets I 8 and I9 to the pad. a rubberized tape 22,cemented or vulcanized to the foam rubber pad along the lower bevelededge I1, may be secured by the stitching 20 to the upper and lowersheets, the lower sheet I 9 being outside of tape 22 as Vshown in Fig.6. Tape 22 of course strong anchorage for the upper and lower coverpression,

the foam rubber pad that yields with the pad when the latter iscompressed but is otherwise practically immovable relative to the pad.

To provide an envelope, casing or compartment for the spring uit, heavycotton duck or other porous fabric walls 23 are attached along theirupper margins, as by stitching @24, to thecover sheet I9 and tape 22,Fig. 6, thus securing the pad Iii and its covering to the compartmentenclosing the spring unit. Walls 23 may be integral with or sewed alonga seam 25 to a bottom fabric wall 25a which completes the envelope orcasing, there being four walls 23 which provide two side walls and twoend walls.

At one end of the envelope the material of the end wall and theadjoining side walls is slitted or divided, as at 26, to make an openinglarge .enough to admit thespring unit I 0 endwise, if v the spring unitis compressed as illustrated in Fig. 2, and suitable fastening elements,such as snap fasteners 21, may be employed to seal the opening (seeFig. 1) when'the spring unit is inside the envelope. It will beappreciated, of course.' that the opening 26, preferably, will be soconstructed that the fabric forms overlapping lips for properoperation-of the fastening elements, as clearly seen in Figs. l and 2.

The height or width of walls 23, preferably, is such that the springunit is somewhat compressed throughout its area when it is within theenvelope.

Thus the walls 23 are maintained under tension except when the mattressis supporting a load as shown in Fig. 4. The reaction from thecompression oi' the spring unit tends to hold the heavy wire frames I Iin the inside corners formed at the upper and lower margins of the sideand end walls, as' seen in Figs. 3 and 6.

Wh'en it is desired to separate vthe spring unit I0 from its envelope,the fastening means 21 are separated and the opening 26 is spread apartwhereupon the envelope or ticking', and contained rubber pad, may bedrawn off the spring unit, as will be clear from Fig. 2. When insertinga spring unit, the cotton or other padding II a which covers all of themarginal wires II will facilitate sliding the unit, and the fabric sheetI9 on the bottom of the pad I4 cooperates in making the introduction ofthe unit, ev'en though under comaA relatively easy operation. Otherspring units of different resiliencies or load-capacities may besubstituted at any time for the unit I0 in a mattress of t'he inventionto adapt the mattress to the comfort or whim of the user.

. Thus the invention is especially valuable for use .extends all aroundthe pad and affords a very l in hospitals, hotels and wherever thepublic is particularly catered to. When maximum comfort is desired, asin a hotel, the mattress will be supported probably on box springs 28 ofconventional form (Figs. 1 and 4). Of prime importance, however, is thefact that the described removable envelope, and contained pad, may bereadily removed from the spring unit and washed and sterilized as aunit, without any injurious effect, and this feature is obviously of thegreatest importance in hospitals and asylums.

Another feature of the invention is the extraordinary provision .forthorough ventilation lof the mattress. The foam rubber itself isessentially a mass of intercommunicating air cells formed in vulcanizedlatex, and it permits continuous circulation of air; a circulation whichis mattress.

foam rubber against the tearingor cutting action of the upper ends ofthe coil springs I2, and as previously stated, assists in facilitatingsliding of room, etc. The cavities-I6 play an important Y part inVentilating the mattress, as the cavity walls are collapsed by theweight of a body lying on the mattress, and the extent of collapse oithe walls of each cup-like recess or cavity I depends upon the weight orcompressive stress imposed on that part of the pad Il. The body of aperson lying on a mattress is constantly shifting or changing itsposition, and with every movement of `every limb, with every turnof thehead orl trunk, the walls defining some of the cavities it are deformedand compressed or are relieved of pressure, the result being a continualcompression l of air in the different cavities, followed by relief ofsuch compression as the air seeps through the porous fabric It coveringthe openings in said cavities. The sudden compression oi air in anycavity also causes some of the air to be forced through theintercommunicating air cells ol the roam rubber pad and thus ventilationof the padl itseli, which normally takes place very slowly butcontinuously, is accelerated by normal use oi" the lt will be understoodthat the ventilat- -ing aircurrents which constantly pass through the vmattress oi the invention are entirely unnoticeable and do not in anyway detract from the oomi-"ort oi the user. On the other hand adequateventilation oi' the mattress will usually enhance the conilort oi theuser. especially in hot weather, as will he understood without furtherdescription.

le the cavities or recesses lb are distributed uniformly over thegreater part of the area of the underside of the loam rubber pad, asbest shown in, rigid there is an area adjacent the marginal wires I i oithe spring unit where the loam rubber pad has no cavities and henceodors adequate padding for the wires Il, which would be veryuncomfortable if felt through the pad.

I; en one sits on the side ofthe bed, the projecting or overlappingportion of the pad will bend or iold down, again to prevent discomfortfrom the Wires I I. This downward bending or folding takes place morereadily because of the bevellng It and vlll oi the edges of the pad.said beveling making `the pad edges much more exible.

When a person lies down on the mattress, the top pad cover I8 will bedepressed (Fig. fiiwith concomitant compression of the foam rubber pad,and as pad cover I8 tits smoothly over the top Asurfaceot the pad,central downward depression of pad cover I8 will cause a tension in thepad cover adjacentboth side'edges and, this vtension will lift thebeveled edges of the foam rubber pad and will tend to pull said edgesinwardly. The pad and its covers I8 and I9 areA free to move inwardlyrelative to the upper 'marginal wires il because they are not fast tosaid marginal wires,

and with slight downward movement oi .either of the upper marginal wireslI, responsive to compression, the side wall 23 may slide overthe wire aVmodification of the present invention, wherein `two spring units. ofdidering characteristics are` employed. ln this form there has beenshown,

thespring' unit into its envelope or compartment.

A further'function oi'-v sheet I9 is to cooperate with the foam rubberin insulating the coil springs, which, being of metal, will' draw ofibody heat rapidly in a cold room. A

Desirably the spring .unit is so made that the coil springs in thecenter are slightly higher than those at the margins adjacent wires il.This `causes the spring unit to have a slight crown or convexity whichis imparted to the top oi the rubber pad when the mattress is assembled,as

best shown in Fig. 3. Thus the mattress'has a better appearance and ismore readily sold.

In Fig. 7, as previously indicated, there is` shown for purposes ofillustration, the same, type oi integrated envelope or tic, andcontained sponge rubber pad, as previously described. rlhus there isseen the pad it, with its enveloping cover layers it and it, thedepending walls it, and the bottom wall tta, the space wit the saidwalls accounmodatlng a pair ol springs as will presently be described.The end wall, seen partially in elevation, is preferably provided with amouth or opening adapted to he normally maintained closed by thefasteners tl, in the manner and tor the purpose previoy described.

in the presentpinstance the vertical length of the side and end wallsiii is somewhat greater than in the nrst described io ci the invention,thus providing an enclosed space below the pad iii ci substantiallygreater depth. This enclosed A space'is divided by a horizontal fabricpartition II and follow the pad in its inward movement.

' iii, which may be stitched or otherwise attached along its margins tothe walls it, into two superposed compartments iii and lit, each. ofwhich is adapted to accommodate a separate individual `A coil springunit, as indicated by the numerals di and it. Thus it is possible toprovide the mattress oi Fig. 'i with a; pair oi springs oi aideringcharacteristics, and this end may be accomplished .by having thecompartments ti and il ci substantially equal depth and utilizing, inone compartment, a spring unit of heavier construction or gauge'thanthat employed inthe other.

However, I prefer to so construct the ticking that the depth orthickness'oi the upper compertinent di is materially greater than thatof theY lower compartment 32, to snugly accommodate spring units ofcorresponding depth or tains, also under slight compression, a coilspring 4 unit of about four inches inthickness; an overall spring heightoi. about ten inches.

One advantage of such an arrangement is that the upper spring unit maybe vof a fairly readily depressible nature so as to respond easily todepressive forces and thus contribute factors of softness and comfort,while the lower unit may have a' stiffer, 'stronger spring action so asto aiord a firm foundation mize sagging tendencies. Since the lowerspring unit .Il is not required or desired to yield downwardly to theextent necessarydn the case of the and 4prevent or minie l such asburlap or the like,

upper unit 33, the former may be of relatively small depth as comparedwith the latter.

`Thus, it will be readily appreciated that the' provision of a mattresshaving a surface or top pad of sponge rubber and an underlying assemblyof spring units of differing supporting cheracteristics, all enclosedwithin an integrated envelope or ticking, constitutes, in and of itself,e, novel and advantageous contribution to the ort. Accordingly, whilethis arrangement has been shown in e; ticking equipped with thedesirable feature of the spring removal opening 2t, it will escasosnection with certain types of spring and a certain kind of foamrubberpaci, other spring units and pads might be used, and variouschanges and modincations may be de without departing 'from thelprinciples of my invention, the scope of which is to be determined bythe appended claim.

'What I claim is:

A unitary composite spring,r and pod mattress structure comprising afabric envelope with septrate upper and lower` compartments, o let coilspring assembly in the lower compartment end a flat spongy rubber pad inthe upper comportment and extending marginally outward beyond thesurrounding wall of the lower compartment, and an attaching strip orfabric extending oround the spongy rubber pad end edhesively secured tothe underside of the outwerdly erbtending margin thereof, said attachingstrip being secured along its outer margin to the periphery of the uppercompartment and elong its inner margin to the top oi' the surroundingwall of the lower compartment.

MARION MORGAN CUNNINGHAM.

